Multilayer fuel tank with cover and fuel vapor collection chamber

Abstract

A multilayered fuel tank ( 10 ) for a motor vehicle is disclosed having a fuel tank body ( 32 ) for holding liquid and vapor fuel comprising a bottom wall ( 46 ), side walls ( 45 ) and a top wall and a plurality of fuel tank components ( 35 ) located on the top wall and seams ( 37 ) located on the side walls. A tank cover ( 36 ) is connected to the fuel tank body to define a vapor collection chamber ( 34 ). The tank cover encapsulates the top wall and the fuel tank components and seams thereby trapping any fuel vapors that may escape from the tank body, the fuel tank components and the seams. Also disclosed is a method of making the multilayered fuel tank and a method of preventing fuel vapors from escaping from a fuel tank to the environment.

What is claimed is:  
     
       1. A multilayered fuel tank for a motor vehicle, comprising: 
       (a) a fuel tank body for holding liquid and vapour fuel comprising a bottom wall, side walls and a top wall;  
       (b) a plurality of fuel tank components located on the top wall and scams located on the side walls; and  
       (c) a tank cover connected to an upper portion of the fuel tank body and defining a vapour collection chamber around the upper portion of the fuel tank, the tank cover protecting and encapsulating the top wall and the fuel tank components and seams thereby trapping any fuel vapours that escape from the tank body, the fuel tank components and the seams.  
     
     
       2. The multilayered fuel tank of  claim 1 , wherein the tank cover and tank body are made of plastic material and the tank cover is bonded to the fuel tank using a bonding method selected from the group consisting of infrared contact free welding, ultrasonic welding and emabond. 
     
     
       3. The multilayered fuel tank of  claim 1 , further comprising a charcoal cannister filter in operative connection with the vapour collection chamber wherein any fuel vapour in the collection chamber is directed to and captured in the charcoal cannister filter. 
     
     
       4. The multilayered fuel tank of  claim 3 , wherein the charcoal cannister filter is also operatively connected to the motor vehicle engine such that the fuel vapour captured by the charcoal filter is then directed to the engine for combustion. 
     
     
       5. The multilayered fuel tank of  claim 1 , wherein the fuel tank components and seams comprise one or more of valves, hoses, connectors, tank body seams, and cables. 
     
     
       6. The multilayered fuel tank of  claim 5 , wherein the tank cover further provides mechanical protection for the tank components and seams during installation of the fuel tank or during a motor vehicle accident. 
     
     
       7. An accessory for a motor vehicle fuel tank comprising a bottom wall, side walls, a top wall, seams and a plurality of fuel tank components located on the top wall, the accessory comprising: 
       a tank cover for connection to an upper portion of the fuel tank to define a vapour collection chamber around the upper portion of the fuel tank, the tank cover protecting and encapsulating the top wall, the fuel tank components ad the seems thereby trapping any fuel vapour that may escape from the tan body, the fuel tank components and the seams during use of the fuel tank.  
     
     
       8. The accessory of  claim 7 , wherein the fuel tank further comprises a charcoal cannister filter in operative connection with the vapour collection chamber and the motor vehicle engine wherein any fuel vapour in the collection chamber is directed to and captured in the charcoal cannister filter and then directed to the engine for combustion during operation of the motor vehicle. 
     
     
       9. A method of making a multilayered fuel tank for preventing the escape of fuel vapour to the environment, the method comprising: 
       (a) providing a fuel tank body for holding liquid fuel and vapour comprising a bottom wall, side walls and a top wall mud a plurality of fuel tank components located on the top wall and scans located on the side walls; and  
       (b) connecting a tank cover to an upper portion of the fuel tank body, the tank cover defining a vapour collection chamber around the upper portion of the fuel tank and protecting and encapsulating the top wall and the fuel tank components and seams thereby trapping any fuel vapours that may escape from the tank body, the fuel tank components and the seams when in use.  
     
     
       10. The method of  claim 9 , further comprising the step of: 
       (a) operatively connecting a charcoal cannister filter with the vapour collection chamber and the motor vehicle engine wherein in use any fuel vapour in the collection chamber is directed to and captured in the charcoal cannister filter and then directed to the engine for combustion.  
     
     
       11. A method of preventing fuel vapour from escaping from a fuel tank for motor vehicles to the environment, comprising: 
       (c) providing a fuel tank body for holding liquid fuel and vapour comprising a bottom wall, side walls and a top wall, and a plurality of fuel tank components located on the top wall and seams located on the side walls;  
       (d) connecting a tank cover to an upper portion of the fuel tank body, the tank cover defining a vapour collection chamber around the upper portion of the fuel tank and protecting and encapsulating the top wall and the fuel tank components and seams thereby trapping any fuel vapours that may escape from the tank body, the fuel tank components and the seams; and  
       (e) directing the trapped fuel vapours through a charcoal cannister filter to the motor vehicle engine for combustion.  
     
     
       12. The multi-layered fuel tank of  claim 1 , wherein the tank cover is connected to the fuel tank body at a plurality of locations, at least one location is on the side walls between the seams and the bottom wall, and at least one location is on the top wall. 
     
     
       13. The multi-layered fuel tank of  claim 12 , wherein the tank cover is connected to the fuel tank body at a plurality of locations on the top wall, so as to provide additional stiffness to the top wall and additional dampening of noise created by a fuel pump located on the top wall. 
     
     
       14. The accessory of  claim 7 , wherein the tank cover is connected to the fuel tank body at a plurality of locations, at least one location is on the side walls between the seams and the bottom wall, and at least one location is on the top wall. 
     
     
       15. The accessory of  claim 13 , wherein the tank cover is connected to the fuel tank body at a plurality of locations on the top wall, so as to provide additional stiffness to the top wall and additional dampening of noise created by a fuel pump located on the top wall. 
     
     
       16. The method of  claim 9 , in which the tank cover is connected to the fuel tank body at a plurality of locations on the top wall, so as to provide additional stiffness to the top wall and additional dampening of noise created by a fuel pump located on the top wall. 
     
     
       17. The method of  claim 16 , wherein the tank cover is connected to the fuel tank body at a plurality of locations on the top wall, so as to provide additional stiffness to the top wall and additional dampening of noise created by a fuel pump located on the top wall.